How to Design Electric Vehicles (EVs)

Transcription

1 How to Design Electric Vehicles (EVs) Course Syllabus, IAP 2016 Non-Credit Course Instructors Ryan Chin, Managing Director & Research Scientist, MIT Media Lab, City Science Initiative Lennon Rodgers, Research Scientist, MIT International Design Center Sanjay Sarma, Professor of Mechanical Engineering, MIT Mechanical Engineering Guest Instructors Rick Chamberlain, Chief Technology Officer, Boston-Power Inc. Eric Carlson, Senior Fellow, Boston-Power, Inc. Craig Carlson, Executive Advisor, Parthenon EY Course Description: If you are interested in designing and building electric vehicles (EVs), then this IAP class is for you. This hands-on course brings together industry experts, MIT faculty, staff, and students to present the basic building blocks to EVs including: battery systems, electric motors, motor controllers, and the overall vehicle systems integration. Each session will delve into practical engineering issues through interactive presentations by instructors and guest speakers. There will also be working sessions conducted by student mentors. The course will address the following questions: How to specify batteries, motor controllers, and motors to satisfy vehicle performance and efficiency goals How to integrate cooling, electrical, and communications systems that are crucial to the operation of EVs How to evaluate technology options How to make design decisions related to overall system and subsystem specification and selection In addition to lectures, this year we will be offering three hands-on lab sessions in order for participants to apply lessons from the talks to practical in-class exercises that emphasize learning by doing and peerto-peer collaboration. The remaining sessions will focus on current market trends, cost challenges, competitive technologies, and future applications including urban mobility, EV infrastructure, energy storage for utilities, and the role of policy and incentives. Schedule Lectures 9am to 12pm on January 19, 20, 21, 26, 27, 28 in E Labs 9am to 4pm on January 22, 25, 29 in the International Design Center (IDC) in N52, 3 rd floor Enrollment Advance sign-up required by Jan. 15 th, Course size is limited to 40 (lecture) and 14 (labs). Students can sign up for both lecture and lab sessions. If the course is oversubscribed, a short essay will be required for selection. Sign-up for the course at this link:

2 Prerequisites Permission of Instructor Attendance Participants welcome at individual sessions Sponsors Mechanical Engineering Contacts Ryan Chin, E15-368D, Lennon Rodgers, N52-387A, Lectures (1) Course Introduction and Batteries (Jan. 19) This session will introduce the goals of the overall course; provide an overview of EV battery systems with a focus on Li-ion technology (history, cell chemistries and attributes, cell designs and components, performance metrics, cell dynamics and models, safety, battery management); and next generation battery chemistries. Speakers: Ryan Chin, Rick Chamberlain, Eric Carlson Guest Speakers: Betar Gallant, MIT Mechanical Engineering (2) Controllers and Electric Motors (Jan. 20) Led by guest speakers from Protean Electric, this session will focus on the design of controllers and electric motors. This session will also present a case study of building an electric motorcycle for the Isle of Man TT Zero race. Speakers: Lennon Rodgers Guest Speakers: Chris Hilton, CTO, Protean Electric (3) Battery Pack Design (Jan. 21) This session will focus on pack design with consideration of design requirements, the specification process and vehicle integration, packaging options from cell to module to pack, thermal management, current collection, safety (mitigation of cell failures), pack testing, and design for impact energy absorption and crashworthiness. Guest Speakers: Dale Robertson, Boston-Power, Inc. Elham Sahraei, MIT Impact and Crashworthiness Laboratory (4) Powertrain Integration (Jan 26) This session will provide an automotive OEM perspective on overall vehicle integration for EVs.

3 Guest Speakers: OEM (1) Greg Hubbard, Senior Engineer for Chevy Bolt, General Motors (GM) OEM (2) Ford (TBC) OEM (3) Tesla (TBC) (5) Applications and Markets (Jan. 27) This session will cover trends and existing and future markets for traditional EVs, new urban vehicles, on-demand systems, and self-driving vehicles. Speakers: Craig Carlson, Ryan Chin Guest Speaker: Zipcar or Car2go (TBD) (6) EV Infrastructure and MIT Student Clubs (Jan. 28) This session will cover EV infrastructure including electric charging, vehicle-to-grid, second life EV battery re-use, and new markets (e.g., home energy management systems). This session will also introduce the EV ecosystem of MIT student research projects and clubs including Formula SAE, Electric Vehicle Team, Solar Car, etc. Speakers: Ryan Chin, Lennon Rodgers Guest Speakers: Praveen Subramani, Energy Partnerships, NEST Michael Lin, MIT Media Lab Charles Guan, MIT-SUTD Collaboration (TBC) Ivan Huang, MIT Campus EVs Representatives from MIT EVT, Solar Car, Formula SAE Labs (limited to 14 students) All of the labs below will be a very hands-on introduction to topics related to electric vehicle engineering. (1) Vehicle Systems Lab (Jan. 22) Main components of electric vehicles (e.g. motors, controller, high voltage, low voltage, contactors). Model and electric vehicle to estimate power and energy with application to range estimation. Sensors and microcontrollers to measure vehicle energy. Extra topics: PID speed controllers. Instructor: Lennon Rodgers (2) Battery Lab (Jan. 25)

4 The full day battery laboratory will be a more in-depth hands-on session of selected lecture topics. Key questions addressed will include: How to charge a lithium-ion cell? What are critical control parameters and metrics? How to verify manufacturer cell specifications? How to characterize continuous and pulse discharge performance and to use this data to develop a dynamic cell model? Specific topics covered include: Laboratory safety while working with high voltage high power battery packs Battery test equipment and how to make measurements Charging and discharging (continuous and pulse) cells Data collection and analysis (extraction of key performance metrics) Instructor: Eric Carlson, Lennon Rodgers, Dylan Urb (3) Motor Lab (Jan. 29) Power electronics Tuning of electronics to motor characteristics Use of dynamometer Instructor: Lennon Rodgers, Dylan Urb

5 How to Design Electric Vehicles (EVs) IAP 2015 Non-Credit Course Schedule Lectures held in E Labs held in N52, third floor Tuesday, January 19 th am Course Introduction Ryan Chin and Sanjay Sarma am Battery Systems for EV s Eric Carlson (Boston-Power, Inc) am Break pm Next Generation Battery Chemistries Betar Gallant, MIT MechE Wednesday, January 20 nd am Electric Motors and Controllers for EVs Chris Hilton (Protean Electric) am Break am Electric Motorcycles at the Isle of Man Lennon Rodgers pm End of day summary Thursday, January 21 th am Pack Design Dale Robertson (Boston-Power, Inc) am Break pm Pack Safety and Crashworthiness Elham Sahraei (MIT Impact and Crashworthiness Lab) Friday, January 22 nd (Vehicle Systems Lab Session) pm Introduction to motors, controllers, high/low voltage, contactors, range estimation pm Lunch Break pm Sensors and microcontrollers (extra: PID speed controllers). Monday, January 25 th (Battery Lab Session) pm This session will involve: Battery Lab safety lecture, basic cell measurements, charging and discharging cells, and comparison of experimental data pm Lunch Break pm This session will focus on characterization of the transient characteristics of EV cells and how to use this data to estimate RC model parameters. Tuesday, January 26 th am am am pm EV Integration at GM Greg Hubbard, Senior Engineer for Chevy Bolt, General Motors Break EV Integration at Ford Speaker (TBD) from Ford Motor Company End of day summary Wednesday, January 27 th am EV Market Trends Craig Carlson am Shared, Autonomous, Electric Mobility for Cities Ryan Chin

6 am pm Break Shared EVs Speaker from Zipcar or Car2go Thursday, January 28 th am Persuasive Electric Vehicle (PEV) Michael Lin, MIT Media Lab am MIT Campus EV Network Ivan Huang, MIT am MIT EV Clubs (Formula SAE, MIT EV Team, Solar Car) am Break pm EV Infrastructure: V-to-G, second life battery use, and smart charging Praveen Subramani (Nest) via Video Conference. Friday, January 29 th pm pm pm (Motor Lab Session) Morning session (topics TBC) Lunch Break Afternoon session (topics TBC)